Excessive regeneration - Diesel Truck Forum - TheDieselGarage.com
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post #1 of 30 (permalink) Old 04-27-2009, 11:50 PM Thread Starter
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Excessive regeneration

Need some help guys. Mechanics at work are stumped, as am I.

2008 6.7 with Allison 6 speed trans in my UPS truck. Engine has been flawless for 40,000 miles, but last week developed an issue. It went into Regen mode first thing in the morning one day, and stayed that way all day. Next day, same thing. Previous regen was 800 miles before this one, but previous to that one was 3000 miles. My mileage is way down, too. Instead of 10-11mpg, its down to 8-9mpg.

I wrote it up, and the mechanics took it off the road. Couldnt find anything wrong with the DPF, and only code was an EGR code. Sent it to the dealer, and they couldnt find anything wrong with the DPF either.

I get it back today and....it goes into regen on the highway out to my route. Stays in regen until noon, then stops for a couple hours. Starts back into regen around 2pm and lasts until 4pm. After that, it was back to normal.

Whats wrong with this thing? One of our mechanics thinks it could be corroded terminals on the sensor plugs. Other ideas include:
1) Injectors throwing extra fuel
2) DPF sensor is bad
3) Manual Regen switch is bad or grounding out

Any ideas? Is there some way we can check balance rates on this truck to rule out the injectors?

Thanks ahead of time for any help.
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post #2 of 30 (permalink) Old 05-02-2009, 12:01 AM Thread Starter
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I guess the GM section isnt the only one with less-than-adequate traffic here, eh?


Anyway, truck had another 1-1/2 hour regen on the 28th, and also tripped a CEL for about 30 seconds during the day, so the shop pulled it back off the road.

Mechanic scanned it, and found two codes:
A) P2961, which is an EGR code, and was tripped 46 times over the two days the truck was back on the road.
B) P2387, which I think is a turbo vane sensor code. This was tripped only the once, setting the CEL.

Is this of any help for anyone to help diagnose?
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post #3 of 30 (permalink) Old 05-03-2009, 12:25 AM
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When you say they checked the dpf what does that mean? I'd be surprised if they could find a crack is there was one there.

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post #4 of 30 (permalink) Old 05-03-2009, 02:40 PM Thread Starter
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Originally Posted by Rcannon View Post
When you say they checked the dpf what does that mean? I'd be surprised if they could find a crack is there was one there.
Russ, the techs at the dealer did tests on the DPF to see if it was faulty in some way and found nothing out of spec. So its not in the DPF itself, it must be electronics or something that works with the DPF.

One of our mechanics found that the DPF sensor plug connections were corroding from road salt/water, and two of our trucks had DPF issues similar to mine due to this. After properly sealing the DPF sensor plugs, those issues went away on the other two, but not on my truck.

It is possible that the EGR code is being tripped by an air leak in the EGR system somewhere, which is feeding air into the system and raising the temp.



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Last edited by TheBac; 05-03-2009 at 02:45 PM.
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post #5 of 30 (permalink) Old 05-06-2009, 07:06 AM
 
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remove battery connections, both. Ground out the system to remove any charges. Hook the batteries back up and see what happens. .....it's a start.
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post #6 of 30 (permalink) Old 05-08-2009, 03:22 AM Thread Starter
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Asked about the status of the truck yesterday. Mechanic said the dealer was waiting on parts. Said some part of the EGR system was broken, but he did not know what part was broken.
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post #7 of 30 (permalink) Old 05-08-2009, 06:04 AM
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I'd like to know what broke. I wonder if the 3500/2500 trucks have that part? It could explaine a lot with the WAAYY different mileage numbers.
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post #8 of 30 (permalink) Old 05-09-2009, 02:27 AM
 
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so the egr temp code coulde be from outside air entering system that or the egr cooler isnt working as well as it should. sometimes the egr cooler needs to be cleaned. did the mechanic do any checks on the cooler?

the vgt looks like it might be something that could go wrong but if your tech did a vgt actuator test it would have make itself more clear if it was actually defective.

as far as regen goes. it could be that your truck doesn't get enough of a load when you drive route so it goes into active regen. it wouldnt be from the manual switch causing the problem because other perameters need to be met before a stationary cycle (what the manual switch activates) can be started
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post #9 of 30 (permalink) Old 05-09-2009, 12:41 PM Thread Starter
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When I finally get the truck back from the dealer (10 days now ), I'll let you know what was replaced. As for the actualtor test, I do not know if my mechanic did any of that or left it for the dealer.

I deliver in a rural area roughly 180-200miles a day, and am 25-40 miles from the center, so the truck does get enough of a load every day. Regen was only happening every ~3000 miles (about once a month) before this past month, so something changed.

I am curious if excess idle time or continuous start cycles could also be a trigger for regen. The other thing is, maybe one of the wash crew is switching the manual regen on accidentally during the evening, so it then kept forcing regen during the day? I dont know enough about this new DPF system to tell.
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post #10 of 30 (permalink) Old 05-09-2009, 02:03 PM
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Sounds like a faulty DPF pressure sensor. If they get cracked. It throws the truck into regen. Ive replaced 2 so far.

Lets just say not quite stock.
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